Classifications

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  • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
  • B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
  • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
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  • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
  • B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts
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  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• • C—CHEMISTRY; METALLURGY
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  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
  • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
  • C08G65/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group
  • C08G65/4012—Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
  • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
  • C08G65/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group
  • C08G65/4012—Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones
  • C08G65/4018—(I) or (II) containing halogens other than as leaving group (X)
  • C08G65/4025—(I) or (II) containing fluorine other than as leaving group (X)
• • C—CHEMISTRY; METALLURGY
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  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
• • C—CHEMISTRY; METALLURGY
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• • C—CHEMISTRY; METALLURGY
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  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2262/02—Synthetic macromolecular fibres
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  • B32B2262/0269—Aromatic polyamide fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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• • C—CHEMISTRY; METALLURGY
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  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2650/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G2650/28—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type
  • C08G2650/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing oxygen in addition to the ether group
  • C08G2650/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing oxygen in addition to the ether group containing ketone groups, e.g. polyarylethylketones, PEEK or PEK
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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• • C—CHEMISTRY; METALLURGY
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Definitions

• a polymeric material may be used to bond two metal parts together.
• Said second part may have a non-circular cross-section.
• % crystallinity described herein may be measured as described in Example 22.
• the phenylene moieties (Ph) in each repeat unit I and II may independently have 1 ,4- para linkages to atoms to which they are bonded or 1 ,3- meta linkages. Where a phenylene moiety includes 1 ,3- linkages, the moiety will be in the amorphous phase of the polymer. Crystalline phases will include phenylene moieties with 1 ,4- linkages. In many applications it is preferred for the polymeric material to be highly crystalline and, accordingly, the polymeric material preferably includes high levels of phenylene moieties with 1 ,4- linkages.
• Said repeat unit of formula I suitably has the structure
• Said polymer may include at least 68 mol%, preferably at least 71 mol% of repeat units of formula III. Particular advantageous polymers may include at least 72 mol%, or, especially, at least 74 mol% of repeat units of formula III. Said polymer may include less than 90 mol%, suitably 82 mol% or less of repeat units of formula III. Said polymer may include 68 to 82 mol%, preferably 70 to 80 mol%, more preferably 72 to 77 mol% of units of formula III.
• Said polymer may include at least 10 mol%, preferably at least 18 mol%, of repeat units of formula IV.
• Said polymer may include less than 32 mol%, preferably less than 29 mol% of repeat units of formula IV.
• Particularly advantageous polymers may include 28 mol% or less; or 26 mol% or less of repeat units of formula IV.
• Said polymer may include 18 to 32 mol%, preferably 20 to 30 mol%, more preferably 23 to 28 mol% of units of formula IV.
• the sum of the mol% of units of formula III and IV in said polymer is suitably at least 95 mol%, is preferably at least 98 mol%, is more preferably at least 99 mol% and, especially, is about 100mol%.
• the ratio defined as the mol% of units of formula III divided by the mol% of units of formula IV may be in the range 1 .8 to 5.6, is suitably in the range 2.3 to 4 and is preferably in the range 2.6 to 3.3.
• said polymer has a Tg in the range 145°C-155°C, a Tm in the range 300°C to 310°C and the difference between the Tm and Tg is in the range 145°C to 165°C.
• Said polymer may have a crystallinity measured as described in Example 22 of at least
• Said polymer suitably has a melt viscosity (MV) of at least 0.10 kNsm “2 , preferably has a MV of at least 0.15 kNsm "2 , more preferably at least 0.20 kNsm “2 , especially at least 0.25 kNsm “2 .
• Said polymer may be part of a composition which may include said polymer and a filler.
• Said filler may include a fibrous filler or a non-fibrous filler.
• Said filler may include both a fibrous filler and a non-fibrous filler.
• a said fibrous filler may be selected from inorganic fibrous materials, non-melting and high-melting organic fibrous materials, such as aramid fibres, and carbon fibre.
• Said component suitably comprises said first and second parts in direct contact and suitably the bond between the parts is extremely strong. Whilst there may be a mechanical connection between the first and second parts, preferably the first and second parts are secured by chemical interaction between the polymer and metal. Thus, the force needed to separate the first and second parts is suitably greater (e.g. at least 10%, 25% or 50% greater) than the force that would be required to separate the same first and second parts if there was only a mechanical (and no chemical) interaction between the first and second parts.
• the area of the first part in contact with the second part may be at least 1 cm 2 , at least 10cm 2 or at least 25cm 2 .
• a thickness of the first part measured perpendicular to the interface between the first and second parts may be at least 1 mm or at least 2mm. The thickness may be less than 20mm, less than 15mm or less than 10mm.
• a thickness of the second part measured perpendicular to the interface between the first and second parts may be at least 1 mm or at least 2mm.
• the thickness may be less than 20mm, less than 15mm or less than 10mm.
• said first part overlies said second part.
• Said first part may comprise an overmoulded region on said second part.
• a method of making a component comprising: (a) selecting a second part comprising a metal;
• step (c) may comprise contacting said composition with said second part.
• said first part or said precursor of said first part is at a temperature above ambient temperature in step (c). It may be at a temperature of at least 50°C, at least 150°C, at least 250°C, or at least 300°C.
• said polymer may be at a temperature which is greater than its Tm.
• the method may comprise moulding a precursor of said first part (e.g. molten polymer, optionally including fillers) on and/or around said second part.
• Said second part may have a preformed, suitably solid, shape immediately prior to contact with said first part or precursor in step (c). Furthermore, preferably the shape remains substantially unchanged in the method.
• the method preferably includes introducing said second part into a tool, for example a mould such as a mould for injection moulding, and contacting said second part with a precursor of said first part (e.g. molten polymer, optionally including fillers) in said tool.
• a precursor of said first part e.g. molten polymer, optionally including fillers
• formation of said first part may comprise injection moulding, for example using a precursor of said first part.
• a precursor of said first part is overmoulded on said second part.
• said second part is preferably treated to alter its surface with which said first part or precursor is subsequently contacted.
• said surface may be treated to remove contaminants and/or to remove grease and/or to chemically modify the surface and/or to alter the surface profile.
• Treatment of said surface may be selected from flame treatment, mechanical abrasion (e.g. shot blasting) and chemical treatment (e.g. etching).
• Said Fe 3+ compound suitably includes sulphate moieties.
• the only cations in said Fe 3+ compound are preferably Fe 3+ .
• the only anions in said Fe 3+ compound are preferably S0 4 2" .
• Said Fe 3+ compound is preferably a ferric sulphate. Said ferric sulphate may be dehydrated or hyd rated.
• Said oxidizing formulation suitably includes at least 6 wt%, preferably at least 10 wt%, more preferably at least 13 wt% of Fe 2 (S0 4 ) 3 , on a dry matter basis (i.e. excluding any water of hydration that may have been included in the ferric sulphate prior to incorporation into the oxidizing formulation).
• Said oxidizing formulation may include less than 30 wt%, less than 25 wt% or less than 20wt% of Fe 2 (S0 4 ) 3 on the same basis.
• Said oxidizing formulation preferably includes a strong acid.
• Said formulation suitably has a pH of less than 1 , preferably less than 0.5, more preferably less than 0.1.
• Said oxidizing formulation preferably includes sulphuric acid, suitably having a concentration of at least 95%, preferably at least 96%. The concentration may be less than 100% or less than 99.5%.
• Said formulation suitably includes 10 to 40 wt% of sulphuric acid having a concentration in a range 95 to 99.5%.
• said oxidizing formulation includes 10 to 30 wt% of sulphuric acid of concentration 96 to 99%.
• Said oxidizing formulation may include other components at a weight in the range 0 to 5 wt%, for example 0 to 2 wt%.
• the balance in said formulation is preferably water.
• Said formulation may include 40 to 84 wt%, preferably 60 to 80 wt%, for example 70 to 80 wt% water.
• Said oxidizing formulation may include 6 to 30 wt% (preferably 6 to 15 wt%) Fe 2 (S0 4 ) 3 , 10 to 40 wt% (preferably 10 to 20 wt%) of sulphuric acid of concentration in the range 95 to 100% (preferably 96% to 99.5%) and 30 to 84 wt% (preferably 65 to 84 wt%) water.
• Treatment of said second part is preferably undertaken at a temperature of greater than ambient temperature, for example at greater than 40°C or greater than 50°C; it may be undertaken at a temperature in the range 50 to 70°C.
• at least a surface of the second part (which surface is to make contact with said first part) (hereinafter referred to as "the bonding surface" of the second part) is contacted with said oxidizing formulation, suitably for at least 5 minutes; and suitably for less than 60 minutes or less than 25 minutes.
• the second part may be immersed in said oxidizing formulation.
• the time between the end of the first step, suitably after the first component is removed from contact with a mass of said oxidizing formulation, is suitably less than 3 hours or less than 2 hours. Steps may be taken to limit contact of the first component with ambient oxygen after the first step.
• said first part (especially the bonding surface thereof) may be washed, suitably with a solvent which comprises or consists essentially of, water.
• said process comprises a step (a)*, prior to said first step.
• Step (a)* suitably comprises treating said second part (especially the bonding surface thereof) to clean it, remove contaminants, or remove oxide and/or an oxide layer. Removal of an oxide layer (e.g. an aluminium oxide layer) may be especially important wherein said metal comprises aluminium.
• Treatment of said second part to clean it may comprise contacting said second part with a cleaning formulation comprising an acid.
• Said cleaning formulation preferably includes sulphuric acid; it preferably also includes nitric acid (e.g. having a concentration in the range 10 to 50% or 20 to 35%).
• Said sulphuric acid may be concentrated, suitably having a concentration in the range 95 to 99.5%.
• step (a)* said treatment is preferably undertaken at a temperature of greater than ambient temperature, for example at greater than 40°C or greater than 50°C; it may be undertaken at a temperature in the range 50 to 70°C.
• step (a)* at least a surface of the second part (which surface is to make contact with said first part) is contacted with said cleaning formulation, suitably for at least 5 minutes; and suitably for less than 60 minutes or less than 25 minutes.
• the second part may be immersed in said cleaning formulation.
• said second part (especially the bonding surface of the second part) may be cleaned with an organic solvent, for example acetone.
• an organic solvent for example acetone.
• said second part (especially the bonding surface of the second part) may be cleaned with an organic solvent, for example acetone.
• an organic solvent for example acetone.
• the invention of the first aspect extends to a component of the first aspect, wherein a residual iron-containing compound is associated with the assembly, for example between the first and second parts.
• the iron compound may comprise residue remaining after the process of the second aspect has been carried out.
• the iron compound may comprise Fe 2+ .
• the iron compound may be FeS0 4 .
• a sulphur-containing compound e.g. an S0 4 2" -containing compound
• a sulphur-containing compound is associated with the component for example between the first and second parts.
• said aluminium suitably includes a continuous aluminium oxide layer which may be corrosion resistant.
• the oxide layer is suitably pitted and said polymer of the first aspect is preferably present in the pits.
• the melt viscosity (MV) of the polymer is preferably such, during the process, that it can flow into the pits suitably to "key" the polymer to the aluminium.
• Said component of the first aspect is preferably a part of an electronics device, for example part of a casing of an electronics device, for example a mobile communications device.
• Said assembly may be a casing for a mobile phone.
• said component may be for an aerospace or automotive application. For example, it may be a part of an aeroplane or vehicle.
• Polymer composition E PEEK 90G TL20 GL15 - a composition comprising 65 wt% of PEEK 90G, 20 wt% talc and 15 wt% chopped glass fibre (bundle length 3-6 ⁇ and fibre diameter 10 ⁇ ).
• Polymer Composition F - PEEK-PEDEK TL20GL15 - a composition comprising 65 wt% of Polymer Composition B, 20 wt% talc and 15 wt% chopped glass fibre (bundle length 3-6 ⁇ and fibre diameter ⁇ ⁇
• copolymer used in polymer compositions B, C, F and G was made as follows:
• a 300 litre vessel fitted with a lid, stirrer/stirrer guide, nitrogen inlet and outlet was charged with diphenylsulphone (125.52kg) and heated to 150°C.
• diphenylsulphone 125.52kg
• 4'- diflurobenzophenone 44.82kg, 205.4mol
• 1 ,4-dihydroxybenzene (16.518kg, 150mol)
• 4,4'-dihydroxydiphenyl (9.31 1 kg, 50mol) were charged to the vessel.
• the contents were then heated to 160°C.
• dried sodium carbonate (21 .368kg, 201 .6mol) and potassium carbonate (1 .106kg, 8mol) both sieved through a screen with a mesh of 500 micrometres, were added.
• the D50 of the sodium carbonate was 98.7 ⁇ .
• the temperature was raised to 180°C at 1 °C/min and held for 100 minutes.
• the temperature was raised to 200°C at 1 °C/min and held for 20 minutes.
• the temperature was raised to 305°C at 1 °C/min and held until desired melt viscosity was reached, as determined by the torque rise of the stirrer.
• the required torque rise was determined from a calibration graph of torque rise versus MV.
• the reaction mixture was poured via a band caster into a water bath, allowed to cool, milled and washed with acetone and water.
• the resulting polymer powder was dried in a tumble dryer until the contents temperature measured 1 12°C.
• Metal samples were grit blasted with virgin white aluminium oxide for several minutes ensuring that the surface was evenly roughened.
• Metal foil strips were immersed in the sulphuric/nitric acid solution for 30 minutes before being washed with deionised water and dried in a stream of hot air. They were again wiped with acetone and then immersed in the ferric sulphate solution for 8 minutes before being washed with deionised water and dried in an air circulating oven at 1 10°C. The foil strips were stored in a desiccator until bonded. Preparation of test samples subsequently takes place within two hours. The following test procedure was used.
• Dry polymer (7g) was melted and compression moulded at 400°C and 5 tonnes for 2 minutes then quenched in cold water producing an amorphous film of thickness 0.2 - 0.3 mm.
• the film was cut into 75mm x 150mm strips.
• a strip of polymer film was sandwiched between two metal foil strips (75mm x 200mm) treated by one of treatments 1 to 5 to produce a laminate.
• the laminate was then heated to 400°C in the press to melt the polymer before being quenched into cold water, producing a test sample comprising two strips of foil bonded together by polymer; this sample was cut into 3 equal strips (25mm x 200mm) for testing by a T-peel test, as described in Example 3.
• Example 3 T-peel test
• the adhesive bond strength of the samples prepared as previously described was tested according to ISO 1 13399 on an Instron 2736-015 tensile testing machine operating with a 30KN load cell using a T-peel test with a peel rate of 50mm /minute and a peel extension of 200mm.
• Metals may be advantageously overmoulded using compositions comprising the PEEK- PEDEK copolymer as illustrated by the following examples.
• Aluminium ingots (50mm x 25mm x 4mm) were pre-treated either using Treatment 4 above (and overmoulded within 4 hours of etching) or by being sand-blasted using silica sand to produce a surface Ra of 5.
• Samples were moulded on a BOY12A injection moulding machine with a tool temperature of 180°C using moulding conditions as described in the manufacturer's datasheets for polymer composition D.
• polymer Compositions C and G the following conditions were used: barrel temp 325°C to 335°C, nozzle temp 340°C, holding pressure 30bar, injection pressure 140 bar and screw speed 45rpm.
• the surface treated aluminium ingot was placed in the tool and allowed to reach the tool temperature and a layer of polymer (4mm thick) was then moulded on to the surface of the aluminium.
• the overmoulded samples were subjected to lap shear testing in a 3-point bend test with a 64mm span at a speed of 2mm/min and the max load before breakage determined. Results are provided in Table 2.
• Table 2 The maximum load strength demonstrates significantly improved bond strength of aluminium to PEEK-PEDEK compared to aluminium to PEEK.
• Crystallinity referred to herein may be assessed as described in the following example.
• Example 22 Differential Scanning Calorimetry of Polvaryletherketone of Example 1
• Crystallinity may be assessed by several methods for example by density, by IR spectroscopy, by x ray diffraction or by differential scanning calorimetry (DSC).
• the DSC method has been used to evaluate the crystallinity that developed in the polymer of Example 1 using a Mettler Toledo DSC1 Star system with FRS5 sensor.
• the Glass Transition Temperature (Tg), the Melting Temperature (Tm) and Heat of Fusions of Melting (AHm) for the polymer of Example 1 was determined using the following DSC method.
• a dried sample of polymer was compression moulded into an amorphous film, by heating 7g of polymer in a mould at 400°C under a pressure of 50bar for 2 minutes, then quenching in cold water producing a film of dimensions 120 x120mm, with a thickness in the region of 0.20mm.
• An 8mg plus or minus 3mg sample of each film was scanned by DSC as follows:
• Step 1 Perform and record a preliminary thermal cycle by heating the sample from
• Step 2 Hold for 5 minutes.
• Step 4 Re-heat from 30°C to 400°C at 20°C/min, recording the Tg, Tn, Tm, ⁇ and AHm.

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